Interlocking panels



1966 R. 5. WHITE 3,264,649

INTERLOCKING PANELS INVENTOR ROBERT 3. WHITE Kiwi-k ATTORNEY 2, 1966 vR. 5. WHITE 3,264,649

INTERLOCKING PANELS Filed July 16, 1962 2 Sheets-Sheet 2 FIG. 4 FIG.5FIG.6

METALIZED PHENOLIC EPOXY MYLAR RESIN RESIN SHEET SHEET SHEET STEEL F] G7 FRAMEWORK ANTENNA FACE AND REFLECTING FACE BOLTS AND WASHERS INVENTOR.

ROBERT 8. WHITE ATTORNEY United States Patent 3,264,649 INTERLOtJKiNGPANELS Robert S. White, Lake Hiawatha, Nah, assignor to NicoletIndustries, 1112., Florham Park, Ni, a corporation of Delaware FiledJuly 16, 1962, Ser. No. 2143349 7 Ciaims. 3!. 343915) My inventionrelates to an interlocking panel, a multiplicity of which areparticularly adaptable for use in forming an antenna screen. Amultiplicity of my improved interlocking panels may be used also forvarious other purposes, such as an insulating wall for buildings, etc.

The warning system, which is known as White Alice, for use by the US.Government, is in operation at present in Alaska and other Atticregions. The average installation, or station, of the warning system canhandle 143 voice channels at one time through the use of radio telephoneequipment specially developed for the warning system.

The average antenna screen presently used in an installation in thewarning system is approximately 60 feet by 60 feet, Weighs about 100tons, and the total weight of the supporting structure for such screenand other electronic gear is about 300 tons. The complete antenna,including the antenna screen, must withstand 150 mph. winds and a 6 inchice load. Such antenna screens are made up of a series of steel panelswhich are caulked between the edges of each panel, which edges aredouble 45 bevels. The panels weigh about 410 pounds each. The panels ofthe antenna screen must be recaulked at least once a year, whichconsumes a considerable number of work days in a very cold atmosphere.

The presently used antenna screen is a parabolic curve, with each of themultiplicity of individual steel panels being curved horizontally andvertically so that the complete antenna screen will form a paraboliccurve.

The weight factor of the material required to erect a present averageinstallation, or station, including the panels, supporting structure,and other electronic gear, is most important, because such materialquite frequently has to be transported into remote locations byhelicopter.

After a considerable amount of research and development Work, I havedetermined that the substantial equivalent of the parabolic curve of thepresent antenna screen may be obtained by misalignment of the adjoiningedges of individual plane panels, rather than by forming each panelhorizontally and vertically so that the complete antenna screen will bea parabolc curve, Such misalignment, as I term it, may be accomplishedby the use of simple wedge-shaped washers behind each panel where it isbolted to a supporting framework.

One object of my invention is to provide an interlocking plane panel ofsuch construction that an antenna screen may be formed by a multiplicityof such plane individual panels which are misaligned to form a facewhich is the substantial equivalent of an antenna screen of paraboliccurvature.

Another object of my invention is to provide an individual antenna panelwhich has a weight of only approximately twenty percent of the weight ofthe presently used panel, with the resultant antenna screen madetherefrom meeting fully all the requirements of withstanding winds of150 mph. and a 6 inch ice load.

Another object of my invention is to provide an interlocking panel whichmay be readily sealed with material which will withstand temperatures ofl00 F. to +450 F.

Another object of my invention is to provide a panel r fifi lfi CePatented. August 2, 1%65 which when interlocked does not require thatthe joints line up in a straight line, and which panels may bestaggeringly connected in the same manner as normally used in layingcourses of building bricks for walls, houses, etc.

Another object of my invention is to provide a panel wherein either sideof the panel may be used to form the substantial equivalent of therequired parabolic curve of an antenna screen.

Another object of my invention is to provide a panel which may have theattaching holes for connection to the support members drilled at thesite of erection.

Another object of my invention is to provide a panel of such relativelight weight that it is possible to prebuild a plurality of such panelsas subassemblies for the construction of the entire face of the antennascreen.

Another object of my invention is to provide a panel which may beassembled or disassembled without destroying the sealing efiiciency ofthe panels.

Another object of my invention is to provide a panel which may be madein various thicknesses depending upon the requirements for varyingclimatic conditions.

My invention includes the various novel features of construction andarrangement hereinafter more definitely specified.

In said drawings; FIG. 1 is a front elevation of one of my improvedpanels, with a portion of the outer covering removed to show the innercore, said panel being shown interlocked with a fragmentary portion of asecond similar panel.

FIG. 2 is a vertical sectional view of the structure shown in FIG. 1,taken on the line 2-2 in FIG. 1.

FIG. 3 is a fragmentary vertical sectional view, partly in elevation andon a larger scale, showing the connecting means for the panels to asupport member, and the means for misaligning the individual panels toproduce the substantial equivalent of a parabolic curve.

FIG. 4 is a sectional view showing one form of my improved panel inwhich the outer housing for the honeycomb core l is provided with ametalized Mylar film 3a, Mylar being the Well-known commercial name of apolyester film.

FIG. 5 is a sectional view showing another form of my improved panel inwhich the outer housing is formed of a phenolic resin sheet 3b.

FIG. 6 is a sectional View of another form of my improved panel in whichthe outer housing is formed of an epoxy resin sheet 30.

FIG. 7 is a small scale, somewhat diagrammatic view showing an antennascreen mounted on a supporting steel framework and as used in aninstallation in a warning system.

Referring to said drawings; the inner core 1 of my improved panel is ofhoneycomb construction formed from corrugated glass fiber reinforcedasbestos sheets. Such honeycomb construction is normally formed from amultiplicity of layers of such corrugated asbestos sheets which have anatfixed plane bottom sheet. The crests of the corrugations of theasbestos sheets are coated with adhesive and caused to adhere to theunderside of the bottom sheet of the superimposed corrugated asbestossheet, until a honeycomb core of the required height is produced. Ofcourse, a honeycomb core of the desired width may be cut from largerhoneycomb constructions.

The glass fiber reinforced asbestos honeycomb core 1 is encased, orcovered, by an outer housing 2 of phenolic resin, or an epoxy resin, ora fiber glass laminate which has a highly durable, transparent, waterrepellent film of polyethylene tereph'thala-te resin (known commonly asMylar), or aluminum sheet material which has an enamel coating on itsouter surface, or surfaces. The Mylar polyester film is coated With athin metallic film which l '13 can be vacuum metallized to the Mylarfilm. As best shown in FIG. 3, the housing 2 is formed of a frontsection 3 and rear section 4. The front section 3 is provided with apreipheral flange and the rear section 4 is provided with acorresponding peripheral flange '6.- The front and rear sections areassembled one within the" other so as to leave an open spacex8 betweenthe flange 5 of the front section 3 and the flange 6 of the rear sec--tion 4.

As best indicated in FIG. 3, the core 1, front section 3, and rearsection 4 of the housing 2 are completely sealed to atmosphere by asealant indicated at 10. As

would be obvious to anyone skilled in the art, when anantenna screen ofthe order of, say 60' X 60',thas beenv formed completely of amultiplicity of individual panels, such as indicated in FIG. 1, or of amultiplicity of subassemblies of such individual panels, the peripheraledges of the completed antenna screen :would be sealed with a sealant10, such as indicated in FIG. -3.J l find it preferably to use apolyvinyl plastisol sealer, although, as, it is 'wellknown, othersealants having equivalent desirable characteristics may be used andwhich will withstandv temperatures of 'l00 P. to +450 F. As would beobvious to one skilled in the art;-the peripheral top, bottom, andsideedges of the completed antenna screen, vor other structure, are sealedto atmosphere by a sealant.

When a multiplicity of my interlocking panels are used to form anantenna screen, the panels are rigidly secured to supporting structures,such as the U-channel 1'5, by

means of bolts 16. The bolts 16, with a washer 17 on the underside ofthe bolt head, extend through drilled openingsformed in the panels,through the openings in,

the wedge-shaped washers 20 positioned between .the outer face oftherear section 4 and the web 21 of the U-channel 15, through matchingopenings formed in the web 21, andlock washers 23 and nuts 24 aretightly fastened on the inner screw threaded ends of the bolts 16.

The Wedgeshaped washers 20 areHof the well-known square configurationwith a center opening for a bolt therethrough. Such type ofbeveledwashers, or wedgeshaped washers, are readily available on thecommercial markets, and available in varying degrees of angularity ofthe cam face. With the use of such beveled washers 203 between thesupporting frame member and the rear side of the interlocking panels,the plane panels maybe misaligned to form an antenna screen face whichis the substantial equivalent of 'an antenna screen: of paraboliccurvature.

Of course, if my interlocking panelsvare used to form ture; amultiplicity of interlocking substantially plane panels rigid-ly'securedto said supporting structure, each of said multiplicity of interlockingpanels comprising a reinforced asbestos honeycomb core, a rigid outerhous ing completely encasing said core, said outer housing comprising afront section and, a rear section, both said front section andrearsection having integral inwardly turned peripheral flangespositioned one within the other in spaced relationship to provide aspace in which the corresponding flanges of adjacentpanels arepositioned in interlocking relationship with a sealant, a sealant insaid space; and means positioned between the outer face of each rearsectionof each of said interlocking panels and said supporting structureto effect misalignment of each of said interlocking panels with respectto each other;

whereby, the outer face ,of the formed antenna screen I will be of aconfiguration which is the substantial l equivalent ofa parabolicscurve;and; whereby, each of said multiplicity. of interlocking panels form aunitary structure completely sealed to. atmosphere','and saidmultiplicity of interlockingpanels form a unitary structure completelysealed to atmosphere.

2.-An antenna screen comprising a supporting-structure; a multiplicityof interlocking substantially plane;

panels rigidly secured to said supporting structure, each of saidmultiplicityiof interlocking panels comprising a 7 glass fiberreinforced asbestos honeycomb core, a rigid plasticPouter housingcompletely encasing said core, said";

outer housing comprising a frontsection anda rear'section, bothzsaidfront section and rear section having in tegral inwardly turnedperipheral flanges positioned one within the other inspaced relationshipto provide a space in which the corresponding flanges of adjacent panelsare positionedin interlocking relationship with a sealant; t

a polyvinyl plastisol sealant in said space; and meansapositionedbetween tl16".0lll161 face of each rearsection of each of' saidinterlocking panels and said supporting stru'cture to effectmisalignment of each of said interlocking panels with respect to eachother; whereby, the outer face of the formed antenna screen will'be of'aconfiguration'which is the, substantial, equivalent of a parabolic,

curve; and whereby, each of said multiplicity of interlocking panel-sform a unitary structure completely sealed to atmosphere, and saidmultiplicity of interlocking panels form/a unitary structure :completelysealed to atmosphere.

3. An antenna screen comprising a supporting structure; a multiplicityof interlockingv plane panels rigidly.

secured to said supporting structure by bolt and nut means,

each ofsaid multiplicity of. interlocking :plane panels comprising aglass fiber, reinforced asbestos honeycomb,

core, a rigid plastic? outer :housingv completely encasing saidcore,said outer. housing comprising ,a front section and a rear section,'bothsaidfront section and rear section having integralinwardly turnedperipheralfla'nges -positioned one within the other in spacedrelationship to provide a space inwhich the corresponding flanges ofadjacent panels are positioned in interlocking relationshipwith asealant; a polyvinylplastisol sealant in said space;

and wedge shapedwasher means positioned on;said bolt means between theouter-face of each reansection of, each of said interlocking panels andsaid supportingstructure;

to effect misalignment of each of said interlocking plane panels withrespectto each other; whereby,'the .outer face of the formed antennascreen, will be of a configurationwhichis the substantial equivalent ofa parabolic curve; and whereby, each of saidmultiplicity ofinterlocking: panels form a unitary structure completely'sealedtoatmosphere,yvand said multiplicity of interlocking panels form a unitarystructure completely sealed to atmosphere.

4.2A structure as in claim 3,-whereinsaid outer hous-v ing is formedof'phenolic resin. t

5.- A structure as in claim 3, wherein said outerhousing is formed of anepoxy resin.

6. A structure as in claim 3, wherein said outer housing is formed ofafiber-glass laminate which has been coated with metalized Mylar..

7. An antenna screen comprising a sup-porting struca ture; amultiplicity of. interlocking plane panels rigidly secured to saidsupporting ,structurebybolt and nut; means, each of said multiplicity ofinterlocking-plane;

panels comprising a glass fiber reinforced asbestos honeycomb core, .arigid metal outer housing, completely encasing said core, said outerhousing comprising a front section and a rearsection, both said frontsectionsand rear section having integral inwardly turnedperipheralflanges positionedone within the other in spaced relationshipto providea space in which the-corresponding flanges of adjacent panelsare POSltlOllCd,lllzifltCliOCklIlg:IClallOIL- ship with a sealant; apolyvinyl plastisol sealant in said space; and beveled-faced meanspositioned on said bolt means between the outer face of each rearsection of each of said interlocking panels and said supportingstructure to effect misalignment of each of said interlocking planepanels with respect to each other; whereby, the outer face of the formedantenna screen will be of a configuration which is the substantialequivalent of a parabolic curve; and whereby, each of said multiplicityof interlocking panels form a unitary structure completely sealed toatmosphere, and said multiplicity of interlocking panels form a unitarystructure completely sealed to atmosphere.

References Cited by the Examiner UNITED STATES PATENTS Gehnnrich 189-36Parkes 189-34 Creulich 52-578 Giuliani 343-912 Kreitzberg 343-916 XHolland et al. 343-915 Tuttle 189-36 McIlroy et al. 343-915 Banche et al343-915 ELI LIEBERMAN, Primary Examiner.

1. AN ANTENNA SCREEN COMPRISING A SUPPORTING STRUCTURE; A MULTIPLICITYOF INTERLOCKING SUBSTANTIALLY PLANE PANELS RIGIDLY SECURED TO SAIDSUPPORTING STRUCTURE, EACH OF SAID MULTIPLICITY OF INTERLOCKING PANELSCOMPRISING A REINFORCED ASBESTOS HONEYCOMB CORE, A RIGID OUTER HOUSINGCOMPLETELY ENCASING SAID CORE, SAID OUTER HOUSING COMPRISING A FRONTSECTION AND A REAR SECTION, BOTH SAID FRONT SECTION AND REAR SECTIONHAVING INTEGRAL INWARDLY TURNED PERIPHERAL FLANGES POSITIONED ONE WITHINTHE OTHER IN SPACED RELATIONSHIP TO PROVIDE A SPACE IN WHICH THECORRESPONDING FLANGES OF ADJACENT PANELS ARE POSITIONED IN INTERLOCKINGRELATIONSHIP WITH A SEALANT, A SEALANT IN SAID SPACE; AND MEANSPOSITIONED BETWEEN THE OUTER FACE OF EACH REAR SECTION OF EACH OF SAIDINTERLOCKING PANELS AND SAID SUPPORTING STRUCTURE TO EFFECT MISALIGNMENTOF EACH OF SAID INTERLOCKING PANELS WITH RESPECT TO EACH OTHER; WHEREBY,THE OUTER FACE OF THE FORMED ANTENNA SCREEN WILL BE OF A CONFIGURATIONWHICH IS THE SUBSTANTIAL EQUIVALENT OF A PARABOLIC CURVE; AND WHEREBY,EACH OF SAID MULTIPLICITY OF INTERLOCKING PANELS FORM A UNITARYSTRUCTURE COMPLETELY SEALED TO ATMOSPHERE, AND SAID MULTIPLICITY OFINTERLOCKING PANELS FORM A UNITARY STRUCTURE COMPLETELY SEALED TOATMOSPHERE.